Charging Seat Lead Frame With Elastic Clamp Deformation Limit
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Solution Overview
Problem
In existing charging seats, the lack of a deformation limit structure for the elastic clamp in the lead frame leads to plastic deformation, resulting in unstable contact with the PE terminal and affecting system operation.
Innovation Solution
A charging seat lead frame design that includes a frame body with a support part protruding towards the end of the elastic arms to limit deformation, ensuring stable clamping of the signal terminals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If no support part is provided on the frame body, then the elastic clamp has sufficient flexibility to adapt to terminal positions, but the elastic clamp undergoes plastic deformation causing unstable contact
Solution Approach 1:
The frame body is designed with different local properties: the main body remains flexible to accommodate terminal position variations, while the support part protrusion provides localized rigid constraint at the critical deformation point of the elastic clamp, preventing plastic deformation without compromising overall adaptability
Solution Approach 2:
The support part protrusion is pre-configured on the frame body to limit the deformation range of the elastic clamp before plastic deformation can occur. This preliminary structural constraint ensures that the elastic clamp operates within its elastic deformation range, maintaining contact stability from the outset
2Ease of manufacture
If the elastic clamp is designed without deformation limits, then the structure is simple and easy to manufacture, but the elastic clamp plastically deforms affecting system operation
Solution Approach 1:
The elastic clamp structure is segmented into two functional zones: the clamping portion that maintains contact pressure on the terminal, and the deformation portion that flexes within limited ranges defined by the support part protrusion. This segmentation allows the clamp to be manufactured as a single piece while controlling deformation through the geometric constraint of the protrusion
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Prevents plastic deformation of the elastic clamp, enhancing electrical contact stability and reliability of the charging seat.
Implementation Method 1
The first elastic clamp includes a pair of elastic arms exposed from the frame body for clamping a first signal terminal
Data Source
AI summary
A charging seat lead frame comprises a frame body and a first electrical connection member. The first electrical connection member includes a first elastic clamp and a first connection part. The first elastic clamp includes a pair of elastic arms exposed from the frame body for clamping a first signal terminal. The first connection part is fixed in the frame body and is connected to the pair of elastic arms of the first elastic clamp. A support part is formed on the frame body and protrudes towards the end part of the elastic arm to limit the deformation amount of the elastic arm.